Winding technology, pneumatically actuated tension brakes

Winding technology, pneumatically actuated tension brakes Pneumatically actuated tension brakes with internally ventilated brake disc Series 0454 Operation 7.03.00 Properties, areas of application 7.03.00 Construction and installation 7.03.00 Torque variations 7.04.00 Permissible frictional power 7.04.00 Dimensions, design variations 7.05.00 Brake caliper complete 7.06.00 Bracket for brake caliper 7.08.00 Axial Fan 7.09.00 Pneumatically actuated wet-running high power brake Series 0444 Operation 7.11.00 Properties 7.11.00 Installation 7.11.00 Data sheets 7.13.00 Hydraulic power pack with cooler 7.15.00 Cooling oil circuit 7.16.00 Continuous strip tension controllers and continuous strip tension regulators Electronic web tension open-loop control with ultrasonic sensor 7.19.00 TENSIONOR I Series 0087-454-21 7.20.00 TENSIONOR II Series 0087-454-01 7.21.00 TENSIOBAR pneumatic web tension feedback control Series 0087-454-00 7.23.00 TENSIODYN M electronic web tension feedback control for measuring roller systems Series 0087-454-22 7.27.00 CONTREX measurement unit for registering force electonically Series 0087-455-01 7.31.00 TENSIODYN T electronic web tension feedback control for jockey roller systems Series 0087-454-23 7.33.00 Control circuit for flying roll changes Series 0087-454-05 7.37.00 Mechanically actuated pressure regulating valve Series 0087-020-00-003 7.39.00 Contents EN 7.01.00

Pneumatically actuated tension brakes with internally ventilated brake disc Tension brake Operation The splined internal drive hub (1) is connected to the unwinding shaft. Mounted on the drive hub is the brake disc (2) which can move axially. The brake calipers (4) mounted on the flange (3) surround the brake disc. They are actuated by compressed air, pressing the brake pads (5) onto the brake disc. Here the level of the braking pressure determines the braking torque generated. When the brake pressure is removed the diaphragm (6) pulls the piston (7) back into its starting position. The brake pad is lifted off the brake disc, which can then move without any residual torque. Properties, areas of application The brakes are mainly used for continuous braking processes predominantly on unwinding equipment. In controlled or regulated processes the brake is the actuator. In this area the Ortlinghaus tension brake fulfils the following requirements Construction and installation The brake should be arranged so that adequate ventilation is guaranteed. The brake should be accessible for maintenance (checking and replacing the brake pads). sensitive response, low hysteresis facility to switch in or out each caliper good heat dissipation quiet running Ortlinghaus tension brake, the important features are: low friction actuation unit with diaphragm, low volumetric capacity modular construction internally vented brake disc splined internal drive hub dual contact pressure on the friction linings Ortlinghaus control and regulation units for web tension control on unwinding equipment are available for actuation of the brake. Series 0454 EN 7.03.00

Pneumatically actuated tension brakes with internally ventilated brake disc Torque variations The 4 brake sizes with variable, brake caliper numbers, effective piston area and friction material, give a wide range of torques with small increments. Size Coefficient Effective Brake caliper of friction piston area Rated torque 1) in Nm at 6 bar µ % 1 2 3 4 5 6 16 0,4 100 9 18 27 36 - - 100 140 280 420 560 - - 0,4 2) 50 70 140 210 280 - - 25 35 70 105 140 - - 100 100 200 300 400 - - 25 0,3 50 50 100 150 200 - - 25 30 60 90 120 - - 100 50 100 150 200 - - 0,15 50 25 50 75 100 - - 25 15 30 45 60 - - 100 200 400 600 800 1000 1200 0,4 2) 50 100 200 300 400 500 600 25 55 110 165 220 275 330 100 150 300 450 600 750 900 34 0,3 50 70 140 210 280 350 420 25 40 80 120 160 200 240 100 75 150 225 300 375 450 0,15 50 35 70 105 140 175 210 25 20 40 60 80 100 120 100 300 600 900 1200 1500 1800 0,4 2) 50 135 270 405 540 675 810 25 80 160 240 320 400 480 100 230 460 690 920 1150 1380 45 0,3 50 100 200 300 400 500 600 25 60 120 180 240 300 360 100 115 230 345 460 575 690 0,15 50 50 100 150 200 250 300 25 30 60 90 120 150 180 1) The figures in bold face are standard designs. 2) Coefficient of friction 0.4 in Sizes 25, 34, 45 for calipers switched on for emergency or fast stop. Frictional power In unwinding processes the lowest speed (at maximum reel diameter) is the important one Frictional power without forced ventilation Avoid heat build-up due to enclosed installation. Frictional power with forced ventilation Friction power in kw Friction power in kw Speed in min -1 Größe = size Speed in min -1 Series 0454 EN 7.04.00

Pneumatically actuated tension brakes with internally ventilated brake disc Dimensions Mesh guard Fan (inside the mesh guard on size 34 and 45) Series n max Durchmesser Längenmaße min -1 A min A max B CH7 D E F N H J K L M α 1 α 2 n x ß 0454-...-16-000000 4150 15 32 45,0 60 242 185 11 165 163 45 14 57 35 50 90 4 x 90 0454-...-25-000000 2600 20 55 74,4 75 360 203 13 250 165 21 19 42 55 45 90 4 x 90 0454-...-34-000000 1950 25 75 96,0 110 450 280 21 340 165 21 19 25 72 30 60 6 x 60 0454-...-45-000000 1450 40 90 115,0 180 560 375 21 450 165 21 19 23 74 30 60 6 x 60 Volumetric capacity per brake caliper: Size 16 new 3 cm 3 max 5,2 cm 3 Size 25 to 45 new 40 cm 3 max 80 cm 3 Design variations 0454-... -size- 000000 0 without forced ventilation 2 with forced ventilation 0 Friction combination µ 0,4 1 Friction combination µ 0,15 2 Friction combination µ 0,4/0,15 6 Friction combination µ 0,3 7 Friction combination µ 0,3/0,15 1 1 Brake caliper 2 2 Brake caliper 3 3 Brake caliper 4 4 Brake caliper 5 5 Brake caliper only for sizes 34 and 45 6 6 Brake caliper } Series 0454 EN 7.05.00

Brake caliper complete Brake caliper, Build Size 16 (for brake discs Ø 160 mm) 0454-9. 0-16-000. 00 Effective area cm 2 2,4 Swept new cm 3 3,0 volume max cm 3 5,2 Operating min bar 0,1 pressure max bar 6,0 0 Without brake pad 0 Without pneumatic fittings 4 With brake pad 2 With 1 T and 1 swivel fitting Friction coefficientµ = 0,4 Brake caliper, Build Size 34 (for brake discs Ø 250, 340 and 450 mm) 0454-9..-34-000.. 0 0 Without brake pad 1 With brake pad µ 0,15 3 With brake pad µ 0,3 4 With brake pad µ 0,4 0 Normal piston area 1 Piston area reduced 50% 2 Piston area reduced 75% 0 Without pneumatic fittings 2 With 1 T and 1 swivel fitting 0 Without bracket 1454-541-34-010 1 With bracket ( 7.08.00) Brake caliper 0-454- -9.0-9.1-9.2 Effective area cm 2 30,4 14,2 8,3 Swept volume new cm3 40 27 20 max cm 3 80 42 30 Operating min bar 0,1 0,1 0,1 pressure max bar 6,0 6,0 6,0 Series 0454 EN 7.06.00

Brake caliper complete 2 stage brake caliper, Build Size 34 (for brake discs Ø 250, 340 and 450 mm) First stage for controlled and regulated braking processes Second stage for Fast Stop or Emergency braking processes 0454-9.3-34-000.00 0 Without brake pad 1 With brake pad µ = 0,15 3 With brake pad µ = 0,3 4 With brake pad µ = 0,4 0 Without pneumatic fittings 2 With 1 T and 1 swivel fitting Stage 1 Stage 2 (P1) (P2) Effective area cm 2 30,4 32,5 new cm 3 12 13 Swept volume max cm 3 40 46 Operating min bar 0,1 0,5 pressure max bar 6,0 6,0 Series 0454 EN 7.07.00

Bracket for brake caliper Bracket 1454-541-34-010 The bracket can be used to fix the brake caliper directly to the side of the machine. The flange on the tension brake can then be dispensed with. When using the bracket it is possible to arrange more brake callipers around the circumference of the brake disc than when using standard brakes with a flange (See Table). In conjunction with brake discs Brake disc Ø D1 250 340 450 Possible number of brake calipers n 5 7 9 Spacing α 72 51 40 Pitch circle Ø D2 365 450 550 Series 0454 EN 7.08.00

Axial fan for AC voltage Axial fan 0087-035-00-003000 The fan is used for forced ventilation of the brake discs. On tension brakes it is fitted onto the protective grill of the brake as shown in Figure 2. Figure 1 Max. volumetric flow 420 m 3 /h Electricity supply 230 V, 50 Hz Power consumption 22 W Cable with earthed plug 1.5 m Fitting to the protective grill on the series 0-454 Size 16 and 25 Size 34 and 45 Figure 2 Series 0454 EN 7.09.00

Pneumatically actuated wet-running high power brake High power brake Operation The two stage piston (1) which is actuated by compressed air generates an axial load which is transferred to the plate pack through the pressure pin (2) and the pressure pad (3). The level of the braking torque is proportional to the braking pressure applied. After the brake pressure is removed the springs (4) push the pressure pin and the piston back to the starting position. The plate pack has cooling oil flowing through it during the braking process and this carries away any frictional heat generated. Properties Compared with air cooled dry running brakes, the wet- running oil cooled tension brakes on unwinding equipment offer the following advantages: Compact construction, an overall size of around 1/4 that of an air cooled brake. High thermal capacity due to oil circulation independent of the speed of the brake, low frictional surface temperature (Max 90 0 C). Low maintenance due to practically wear-free friction linings. No contamination of cooling air with abrasion dust, as this is a closed system. No noises due to squealing of the friction linings such as are possible with dry-running. Heat exchanger (oil/air - oil/water cooler) can be set up some distance from the machine (possibly in a separate room with a supply of fresh air). The power losses (frictional power) no longer have to be dissipated on the unwinding equipment. Due to its design there is a residual torque in the brake. This depends on the speed, the quality of the cooling oil and the temperature (figures on request). Installation The brake is available in two variations: Variation 1: The brake is flange mounted and centralised on the bearing pedestal (machine stand). Variation 2: The brake is fitted onto the unwinding shaft and secured axially. A torque arm prevents the housing from turning. The torque arm, nuts and bolts must be ordered separately. Variation 2 is selected when it is not possible to centralise the brake on the machine stand. The transfer of torque from the shaft to the internal drive hub can be either through a key and keyway or a locking assembly. Cooling and lubrication materials The friction characteristics of the wet-running high power brake depend largely on the oil quality selected. With unsuitable oils even at low speeds it is possible for chatter to occur in the brake. The oils used contain materials to prevent brake noises. Oils to the following specifications are suitable for use in high power brakes Automatic transmission fluids ATF Type A, Suffix A Series 0444 EN 7.11.00

Pneumatically actuated wet-running high power brake flanged version Cooling oil inlet, marked IN Centralising length Cooling oil outlet Series 0444-000-size-000000 Size 39 47 55 63 Max. friction power kw 9 14 32 45 Braking torque Stage 1 (P1) Nm 200 400 800 1400 Stage 2 (P2) Nm 600 1200 2400 4200 Total Nm 800 1600 3200 5600 Working pressure bar 6 6 6 6 A max H7 50 65 95 120 B 130 155 180 230 C 200 245 305 360 Diameter D 95 98 110 140 E 108 108 120 158 F g7 200 245 305 360 G 6 x M8 6 x M10 6 x M12 12 x M16 H 185 225 282 335 n 3 3 6 6 α 120 120 60 60 M 151 163 200,5 195 N 19 17 20 25 Length O 162 180 215 195 dimensions R 15 15 14,5 15 S 28 29 28,5 30 T -0,2 119 132,8 162-0,3 135-0,3 After the brake has been fitted remove items 1, 2 and 3. Cooling oil flow required can be provided on request Series 0444 EN 7.13.00

Pneumatically actuated wet-running high power brake for torque arm Compressed air P1 Cooling oil inlet, marked IN Compressed air P2 * Cooling oil outlet by choice Torque arm Series 0444-200-size-000000 Size 39 47 55 Max. friction power kw 9 14 32 Braking torque Stage 1 (P1) Nm 200 400 800 Stage 2 (P2) Nm 600 1200 2400 Total Nm 800 1600 3200 Working pressure bar 6 6 6 A max H7 50 65 95 B 130 155 180 C 200 245 305 Diameter D 95 98 110 E 108 108 120 G 6 x M8 6 x M10 6 x M12 H 185 225 282 M 151 163 200,5 N 19 17 20 Length O 162 180 215 dimensions R 15 15 14,5 S 28 29 28,5 T -0,2 119 132,8 162-0,3 U 20 31 35 V 51 80 90 Torque arm 1-444-541-size 000 000 Hex. bolt DIN 931 M8 x 170 M10 x 180 M12 x 220 Grade 10.9 10.9 10,9 Hex. nut DIN 943 M8-10 M10-10 M12-10 Cooling oil flow required can be provided on request Series 0444 EN 7.14.00

Hydraulic power pack with cooler Hydraulic power pack with cooler 0086-237-.. -... Size Cooling power[kw] Pump power Tank volume Dimensions approx. with heat exchanger ca. L x B x H Oil/Air Oil/Water l/min l mm 11 6 15 16 540 x 530 x 540 71 10 22 60 508 x 365 x 1200 82 16 40 40 115 633 x 460 x 1300 82 36 72 65 160 810 x 590 x 1300 96 130 160 400 1514 x 735 x 1700 Version with Oil/Air heat exchanger 1 Tank 2 Oil level indicator 3 Level switch 4 Pump motor 5 Pressure relief valve 6 Temperature regulator 7 Throttle valve 8 Pressure switch 9 Oil cooler with blower motor Series 0444 EN 7.15.00

Pneumatically actuated wet-running high power brake Cooling oil circuit The cooling oil is directed through the disc pack of the brake where it absorbs the frictional heat which has been generated. The heated oil flows back into the tank. Cooling is carried out in an oil/ air or oil/water heat exchanger. The return flow from the brake into the tank should be arranged with minimum backpressure so as to keep the dynamic pressure in the brake as low as possible. For this reason the heat-exchanger is fitted in the feed line. During continuous slipping operation the prescribed oil flow rate for cooling the brake must be ensured. The oil flow rate can be monitored with a flow meter and switch. If the minimum flow rate is not reached a signal will be triggered and the installation brought to a standstill. Filtration of the cooling oil is not necessary for the brake, but is possibly required for the components used in the hydraulic power pack (e.g. changeover valves). Hydraulic power packs with oil/air or oil/ water heat exchangers are part of the Ortlinghaus delivery range. Design examples The following circuit diagrams show some examples of typical basic circuits. These can be varied and supplemented with additional monitoring or display functions. Example 2 The quantity of oil delivered by the pump is fed to the heat exchanger. After this the flow is split. Part of the flow goes directly back to tank, the rest flows as cooling oil through the brake. This circuit is best for cooling powers above 6 kw as at these powers the heat exchanger requires more oil flow than the brake can take. The oil flows are adjusted by throttle valves. Flow meters with switch contacts provide the displays and monitoring of the oil flow. Temperature controlled switching on and off of the fan motor is recommended. Example 1: Circuit diagram for a brake with cooling power up to a maximum of 6 kw. Pump and blower are driven by one motor. Since the oil flow delivered by the pump flows through the heat exchanger and brake without being divided up no flow rate indicator is required. A simple, compact and good value design. Example 3: Cooling oil supply for several brakes through a cooling unit with oil / water heat exchanger. The flow is split after it goes through the heat exchanger. The residual quantity which is not needed for the brake flows directly back to tank. Displaying and monitoring the adjusted oil flow rates is recommended. Oil/water heat exchangers provide a cost-effective alternative when industrial water supplies are available for cooling purposes. Series 0444 EN 7.16.00

Pneumatically actuated wet-running high power brake Example 4: Circuit diagram for two brakes which are fed alternately with cooling oil. For roll change-over machines the cooling oil flow is directed in each case to the active brake. This means that one cooling unit is adequate for two braked axles. A filter is provided to protect the directional control valve. Series 0444 EN 7.17.00

TENSIONOR Electronic web tension open-loop control with ultrasonic sensor TENSIONOR Properties The roll diameter is sensed by the ultrasonic sensor. Levers to sense the roll diameter are not required. Simple operation. Digital display of the operating parameters, ramp function when starting (TENSIONOR II), additional checking and monitoring function. Simple to fit on existing plant. Operation The operating pressure of the brake or the nominal value is pre-selected to suit the desired unwinding tension. The roll diameter is continually scanned by means of an ultrasonic sensor. The braking pressure is controlled as a function of the roll diameter so that the unwinding tension remains constant. The control unit is available in two design variations. Both variations are operated using a membrane key pad and have a digital display, together with, one signal output adjustable for a required residual diameter. Version II has additional display parameters, ramp function when starting up, manual range switch over and Manual/ Automatic mode selection switch. Area of application An alternative to present roller lever controls. Automation of present hand operated equipment. Also for multiple unwinding machines e.g. cross cutting machines. For continuous flow processes with no fast speed changes. Tension: whatever is required, depending on the braking torque available. Sensors for roll diameters up to 800 mm, 1600 mm, larger than 1600 mm. Series 0087-454-21/ 01 EN 7.19.00

TENSIONOR I Electronic web tension open-loop control with ultrasonic sensor Operating panel 0087-454-21-015010 1 ultrasonic sensor 2087-670-11-010005 is included in the delivery specification Operating controls 1 Digital display 2 LED - voltage supply 3 LED - ready for use 4 Button - Brake pressure adjustment 5 Button - Open brake Technical data Dimensions (W x H x T): 200 x 300 x 120mm Supply line: 24 ±10% V DC, 1.2 A Residual ripple 10% Mains pressure: Output: Temperature range: 7 bar filtered 40 µm (NW4) 0-6 bar, (NW4) 0-40 C Ultrasonic sensor 2087-670-11-010005 Scanning range: 170 mm - 1170 mm Supply voltage 24 ±10% V DC, Residual ripple 10% Working temperature: -20 C to +70 C Output signal: Bit pattern Series 0087-454-21-015010 EN 7.20.00

TENSIONOR II Electronic web tension open-loop control with ultrasonic sensor Operating panel 0087-454-01-000000 Operating controls 1 Electronic web tension control unit 2 Switch - Open brake 3 Brake pressure gauge 4 Pressure regulator for manual brake pressure 5 Manual/Automatic mode selection switch 6 Option: Manual range switch-over 7 Option: Adjustable Emergency Off brake pressure Technical data Dimensions (WxHxT): Supply voltage: Signal "Plant running": Mains pressure: Output: Own air consumption: Temperature range: 380 x 300 x 210 mm 230 V, 50 Hz 5-30 V DC 7 bar, 3 µm oil free (NW6) 0-6 bar, (NW4) Max. 13 l/min 0-40 C Digital display The 3 1 /2 character digital display enables precise, repeatable nominal values to be set, It also acts as a check on the following values: - Roll diameter (mm) - Brake pressure (bar) - Set nominal value (%) - Set residual diameter (mm) (greater than the spool diameter) Ramp function When accelerating to working speed there is an adjustable ramped build up of the brakepressure. This avoids or prevents excessive tension forces during the acceleration process. Residual diameter signal When reaching this diameter the controller gives a signal which can trigger a warning message or stop the plant. Holding pressure During a shut down the brake is pressurised with the holding pressure. This keeps the web taut and prevents the roll turning due to out of balance forces. Design variations 0087-454-01-000... Emergency Off circuit 0 With no Emergency Off (standard) 1 with, pressure not adjustable 230 V, 50 Hz 2 with, pressure adjustable 230 V, 50 Hz 3 with, pressure not adjustable 24 V= 4 with, pressure adjustable 24 V= Ultrasonic sensor 0 Measuring range 0.2 0-1.0 m (standard) 1 Measuring range 0.10-0.5 m Manual range switch-over 0 No range switch-over (standard) 1 1 switch for range switch-over 2 2 switches for range switch-over 3 3 switches for range switch-over 4 4 switches for range switch-over Manual operation The brake can be run through a manual pressure regulating valve. Range switch-over When using the ORTLINGHAUS tension brake with several brake calipers, valves can be provided for individual caliper shut-off at the operating panel. Series 0087-454-01 EN 7.21.00

TENSIONOR II Electronic web tension open-loop control with ultrasonic sensor Ultrasonic sensor 2087-670-01-0.0000 Sensor 2087-670-01-...000 is included in the delivery specification of operating panel 0087-454-01-000... output voltage max. 100 ma screen Minimum distance from metal surfaces LED Trimmer for switched output Bl. 1935 Design Variations 2087-670-01-000 Measuring range 0.2-1.0 m, output voltage 2-10 V 2087-670-01-010 Measuring range 0.1-0.5 m, output voltage 1-5 V 2087-670-01-020 Measuring range 0.3-2.0 m, output voltage 3-10 V Technical data Supply voltage: 18-35 V DC Ripple: max. 10% Consumption (without load): 70 ma Ambient temperature: -10 - +50 C Enclosure Class: IP67 Cable length: 2 m Series 0087-454-01 EN 7.22.00

TENSIOBAR Pneumatic web tension feedback control TENSIOBAR Properties Fully pneumatic robust construction, can be used for difficult environmental conditions and in protected areas. Simple operation, maintenance free Automatic, sensitive, repeatable regulation Operation In the measuring device the effective web tension force is compared with the preset nominal value. This comparison results in a pneumatic signal, which controls the working pressure of the brake and automatically compensates for deviations. The measuring device is also the bearing point for a web guide roller, which functions as a measuring roller. The roller deflects only a few tenths of a mm and does not skew on its axis. Area of application Thanks to its ease of handling and robust design it is suitable for difficult environmental conditions. Use in protected areas is possible. Effective tension force of the measuring roller: 30 N to 170 N 60 N to 600 N 200 N to 2000 N Option: Two tension ranges, switchable Series 0087-45. EN 7.23.00

TENSIOBAR Pneumatic web tension feedback control Operating panel 0087-454-00-007... Operating controls 1 Nominal value display 2 Brake pressure indicator 3 Adjustment of nominal value 4 Adjustment of pre-braking pressure 5 Switch - Open brake 6 Manual/Automatic mode selection switch Option: 7 Switch - Braking range switch-over 8 Switch - Nominal value range Technical data Dimensions (W x H x T): 380 x 300 x 210 mm Control Signal Plant running : See Design Variants Mains pressure: 6 bar, filtered 50 µm, Hose NW6 Output: 0-6 bar, Hose NW4 Connection to measuring device: 3 x Hose NW4 Temperature range: 0-40 C Design variations 0087-454-00-007... Switch-over of Nominal Value Range 0 No switch-over (standard) 1 with switch-over of nominal value range I/II Manual range switch-over 0 No range switch-over (standard) 1 1 switch for range switch-over 2 2 switches for range switch-over 3 3 switches for range switch-over 4 4 switches for range switch-over Solenoid valve voltage Plant Running 0 Solenoid valve 24 V DC (standard) 1 Solenoid valve 230 V, 50 Hz 2 Solenoid valve 110 V, 50/60 Hz Series 0087-454-00-007 EN 7.24.00

TENSIOBAR Pneumatic web tension feedback control Measuring unit 0087-456-00-00.000 Strip guide roller Measuring direction continuous shaft required Measuring direction 2 Measuring direction 1 Design Variations: 0087-456-00-005 -000 Web tension 200 N - 2000 N 0087-456-00-006 -000 Web tension 60 N - 600 N 0087-456-00-007 -000 Web tension 30 N - 170 N -000 Measuring unit 1 (standard) -001 Measuring unit 2 The quoted nominal force ranges apply for an area of wrap contact of 90. Other force ranges on enquiry. Resultant bearing load: Compressed air connections: max. 1250 N NW4 1 Compressed air connection 2 Output line 3 Target pressure Series 0087-456 EN 7.25.00

TENSIODYN M Electronic web tension feedback control for measuring roller systems TENSIODYN M Properties For precise, repeatable tension forces PID regulator with adjustable regulation characteristics Digital Nominal/Actual value display Integral DMS measurement amplifier Operation The tension force is registered by means of the CONTREX measuring device or other measuring bearing. After processing the signal from the measurement amplifier in the PID regulator, the brake, on the unwinding equipment, is supplied with the regulated brake pressure through a U/P converter. Adjustable ramp function when starting, Automatic switch-over to holding pressure when the machine is at a standstill. Automatic switching on/off of the brake caliper, other switching and control functions. Area of application For unrolling equipment with demanding requirements, operating convenience, repeatability, automation A wide regulating range and optimum adaptation to process flow Free choice of roll diameter Tension force range dependent on the measuring range of the pick-up: up to 1000 N with the CONTREX measuring device, above 1000 N measuring bearings or load cells. Series 0087-454-22 EN 7.27.00

TENSIODYN M Electronic web tension feedback control for measuring roller systems Operating panel 0087-454-22-0..000 Operating controls 1 PID regulator 2 Switch - Open brake 3 Brake pressure gauge 4 Pressure regulator for manual brake pressure 5 Manual/Automatic mode selection switch Option: 6 Manual range switch-over Technical data Dimensions: (W x H x T) 380 x 300 x 210 mm Supply voltage: 24 V ± 10 % DC, 2 A Residual ripple 10 % Signal Plant running : 5-30 V DC Mains pressure: 7 bar, 50 µm Hose NW6 Output: 0-6 bar Hose NW4 Temperature range: 0-40 C Measurement amplifier for DMS pickup: 350 Ω Supply voltage ±5 V Sensitivity: 0,5-5 mv/v Design variations 0087-454-22-0..... Operating panel 0 With no PID regulator, With no measurement amplifier (MV) 1 With PID regulator, with no MV 2 With PID regulator, With MV (Standard) Ultrasonic sensor to influence the PID regulator 0 Without sensor (standard) 1 With sensor measuring range 0.20-1.0 m 2 With sensor measuring range 0.10-0.5 m 3 With sensor measuring range 0.30-2.0 m Automatic caliper switch on for fast stop 0 Without solenoid valve (standard) 1 With solenoid valve Automatic caliper switch off during winding operation 0 Without (standard) 1 With solenoid valve Manual range switch-over 0 No range switch-over 1 1 switch for range switch-over 2 2 switches for range switch-over 3 3 switches for range switch-over 4 4 switches for range switch-over Series 0087-454-22 EN 7.28.00

TENSIODYN M Electronic web tension feedback control for measuring roller systems PID regulator 0087-454-12-00.-000 Operation - PID regulator function - Integral measurement amplifier for DMS pick-ups (full bridge 350 W, supply voltage ± 5 V), zero point deviation coarse/fine, amplification up to 10.000 times, adjustable damping of the input signal - 3 1 /2 character digital display for nominal values and actual values - Ramped build up of the signal after the start - Extended regulator function after stop - Holding pressure when the machine is at a standstill - Adjustment of the whole regulating characteristics through a potentiometer, fine adjustment possible by separate P, I and D components - Indicator LED for internal supply voltage - Regulator parameters and functions can be adjusted on the face plate - External nominal value setting possible - Supply voltage 24 V DC, 2 A - Output voltage 0-10 V DC Options - Automatic caliper switch off during the unwinding process - Automatic caliper switch on for fast stop or Emergency Off - Automatic adjustment of the regulator during the unwinding process Design variations 0087-454-12-0..000 PID regulator 1 With no measurement amplifier (MV) 2 With measurement amplifier (standard) Ultrasonic sensor to influence the PID regulator 0 Without sensor (standard) 1 With sensor measuring range 0.20-1.0 m 2 With sensor measuring range 0.10-0.5 m 3 With sensor measuring range 0.30-2.0 m Series 0087-454-22 EN 7.29.00

TENSIODYN M Electronic web tension feedback control for measuring roller systems Measurement pick-up Ortlinghaus CONTREX measurement unit, series 0087-456-22-...000, see page 7.32.00 Force range up to 1000 N Web tension load cell series 0087-455-02-00.000 Force range up to 100 N - 10 000 N Web tension sensor series 0087-455-02-005... Force range up to 160 N - 6300 N for fitting with bearing pillow block Various measurement pick-ups are available for registering the web tension force. Precise technical details on request Series 0087-454-22 EN 7.30.00

CONTREX Measurement unit for registering tension force electronically CONTREX Operation The CONTREX measuring device Figure 1 is used to register web tension force and consists of. Measuring unit 0087-456-22-...000 Measurement amplifier with digital display 0087-455-01-005004 When used in a closed regulation circuit the measurement amplifier is integrated in the regulation unit (Ortlinghaus TENSIODYN M). The mechanical components contain the nondisplacement measurement pick-up and the bearing points for a web guide roller. The shaft journals of the roller are fitted into clamped locations. An overload safety device prevents damage to the measurement pick-up. The measuring unit can be fixed as a pedestal or flanged bearing (Figure 2) on the frame of the machine. It is designed for tension forces of 1000 N maximum. The measurement amplifier (Figure 3) is housed in a casing and can be integrated into the electrical cabinet of the machine. The 3 1 /2 character digital display can be adjusted to display the value in kg or N as required. The electrical processing of the signal makes installation possible in places where access is difficult or can allow the display of the web tension to be at a remote operating station (up to 500 m). Figure 1 Figure 3 Figure 2 Series 0087-45. EN 7.31.00

CONTREX Measurement unit for registering tension force electronically Measuring unit 0087-456-22-...000 Web guide roller Measuring direction1 continuous shaft required Measuring direction 2 Measuring direction 1 Measuring range: up to 1000 N (for an area of wrap contact of 90 0) Resultant bearing load: max. 1250 N Design Variations 0087-456-22-004000 Measuring unit 1 (standard) 0087-456-22-004001 Measuring unit 2 Series 0087-456-22 EN 7.32.00

TENSIODYN T Electronic web tension feedback control for jockey roller systems TENSIODYN T Properties For high demands in constant web tension and also for use in dynamic conditions. PID regulator with adjustable regulation characteristics Automatic adjustment of the regulating characteristics as a function of the roll diameter. Regulated position of the jockey pulley regardless of the nominal value. Operation The positional deviation of the jockey pulley is registered by a potentiometer. The PID regulator influences the brake pressure through the U/P converter. To prevent vibrations of the jockey pulley there is an automatic adjustment of the regulating characteristics as a function of the rolldiameter In the regulated state the jockey pulley remains in the adjusted centre position regardless of the nominal value for the web tension. Area of application Where there is a high requirement for a constant web tension and also for use in dynamic conditions when starting the machine, during interruptions to the operation or during speed changes. Free choice of roll diameter and tension force nominal values. Notes the required memory capacity of the jockey pulley system depending on the maximum change of speed. Series 0087-454-23 EN 7.33.00

TENSIODYN T Electronic web tension feedback control for jockey roller systems Operating panel 0087-454-23-0..000 Operating controls 1 PID regulator 2 Switch - Open brake 3 Brake pressure gauge 4 Pressure regulator for manual brake pressure 5 Manual/Automatic mode selection switch Option: 6 Manual range switch-over 7 Pressure regulator with pressure gauge for setting the nominal value for the jockey pulley cylinder Technical data Dimensions (W x H x T): 380 x 300 x 210 mm Supply voltage: 24 V ± 10 % DC, 2 A Residual ripple 10 % Signal Plant running : 5-30 V DC Mains pressure: 7 bar, 50 µm Hose NW6 Output: 0-6 bar Hose NW4 Temperature range: 0-40 C Required jockey pulley potentiometer: 10 kω Design variations 0087-454-23-0..... Operating panel 0 With no PID regulator 1 With PID regulator (standard) 2 With PID regulator and manual setting of nominal values Ultrasonic sensor to influence the PID regulator 1 Measuring range 0.20-1.0 m (standard) 2 Measuring range 0.10-0.5 m 3 Measuring range 0.30-2.0 m Automatic caliper switch on for fast stop 0 Without solenoid valve (standard) 1 With solenoid valve Automatic caliper switch off during winding operation 0 Without solenoid valve 1 With solenoid valve (standard) Manual range switch-over 0 No range switch-over 1 1 switch for range switch-over 2 2 switches for range switch-over 3 3 switches for range switch-over 4 4 switches for range switch-over Series 0087-454-23 EN 7.34.00

TENSIODYN T Electronic web tension feedback control for jockey roller systems PID regulator 0087-454-13-01.000 Operation - PID regulator function - Diameter led regulator adjustment - Integral amplifier for adjustment of the jockey pulley potentiometer - Ramp function - Extended regulator function - Automatic holding pressure - Adjustment of the whole regulating characteristics, fine adjustment possible by separate P, I and D components - Automatic range switch-over - Automatic caliper switch-on for fast stop - Display of jockey pulley position - Display of regulator output - Regulator parameters and functions can be adjusted on the face plate - Indicator lights for internal supply voltage - Supply voltage 24 V DC, 2 A - Output voltage 0-10 V DC Design variations 0087-454-13-01.000 Ultrasonic sensor to influence the PID regulator 1 With sensor measuring range 0.20-1.0 m (standard) 2 With sensor measuring range 0.10-0.5 m 3 With sensor measuring range 0.30-2.0 m Series 0087-454-23 EN 7.35.00

Control circuit for flying roll changes Brake 2 Brake 1 Control circuit for flying roll changes 0-087-454-05-000 Web tension control/regulation e.g. TENSIONOR TENSIOBAR TENSIODYN M TENSIODYN T p Progress of the brake pressure during a roll change (schematic representation) Brake 1 Reel change Reel change t 0 t 1 Brake 2 t 1 t 0 t Series 0087-454-05 EN 7.37.00

Mechanically actuated pressure regulating valve for pneumatic web tension feedback control with jockey pulley arm Pressure regulator with no fixing plate P A * at 1 bar output pressure Connection thread: 1/4 NPT Measurement port: 1/4 NPT Pressure range: 0.14-8 bar Regulating travel: 1.6 mm ±10% Own air consumption: 3 l/min Volumetric flow: 280 l/min Series 0087-020-00-003 EN 7.39.00

Mechanically actuated pressure regulating valve for pneumatic web tension feedback control with jockey pulley arm Design example ON 19.1.04, Sheet 8/03.88 1 Brake caliper 1a Brake caliper for Emergency braking 2 Valve "Open Brake" 3 Valve "Emergency Off" 4 Valve "Automatic/Manual" 5 Pressure regulating valve for manual operation 6 Pressure regulating valve "Nominal value" 7 Pressure regulating valve with plunger 8 Nominal value cylinder Series 0087-020-00-003 EN 7.40.00